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Page 1 of 10©Copyright Meredith Corporation 2012 This easy-to-build mobile tool stand packs a shop full of convenience in a small package. Quick-convert Tablesaw/Router Station Raise the wings for full workpiece support. A router table and accessories stow away in the drawer. Voilà! A router table with fence and plenty of infeed and outfeed support. Tools needed: Overall dimensions when folded are 32 7⁄8" wide × 29 3⁄8" deep × 31 1⁄4" high. Unfolded: 72×48×31 1⁄4". Materials needed: Birch plywood and medium-density fiberboard (MDF). Skill Builders Discover an easy way to table-mount a router. Use guides to accurately position and install hinges. Project Highlights With a footprint of less than 7 square feet when folded, this mobile tool stand expands into a massive 17-square-foot tablesaw work- surface. And it’s multitalented—to switch to a router table, simply slide out the on- board router drawer. See More Resources, page 6, for an idea about compatible stor- age for the tablesaw. MD-00931 Page 2 of 10 Note: The dimensions in this project assume a material thickness of 3⁄4". Most sheet goods will be slightly undersize. In order to ensure that dimensions of subassemblies are correct, measure the thickness of your materials and adjust the length of adjoining project parts to compensate. Construct the carcase 1From 3⁄4" plywood, cut the sides (A), back (B), shelf (C), and base (D) to size. (See Materials List, page 10 .) Predrill and screw the sides to the back as shown [Drawing 1, Photo A]. 2With the case on its back, slide the shelf (C) into place [Drawing 1] and secure with screws. Now, flip the case onto its top. Center the base (D) side-to- side, positioning it 1" from the front of the case, and screw it into place. Drill holes to fit the caster stems and, before A a brace squares the case C quick scrapwood Guides ease hiNGe pLaceMeNt D A squaring brace (see More Resources, page 32) aligns and steadies the sides (A) and back (B) for drilling and screwing. A scrapwood guide held against the back edge of the wing support correctly positions the hinge at 90° while you secure it. Clamp a spacer to the case (1" for the front; 1 1⁄2" for the back). Position the wing support (E) flush with the case top, and secure the hinge. A A B cut two supports froM oNe bLaNk Firm support, a 10-tpi or higher blade, a slow-but-steady cut rate, and zero orbital action ensure a smooth, straight jigsaw cut. E E Scrapwood guide1¼" E A 1" spacer righting the case, install the casters to ease mobility during assembly. 3From 3⁄4" plywood cut three 12×12" blanks, and lay out the wing support (E) dimensions [Drawing 1a]. Use a jigsaw to cut the blank into two supports along the diagonal [Pho to B]. Then, smooth the cuts with a sanding block. 4Use a scrapwood guide as a straight- edge to locate and secure the 2 1⁄2" butt hinges to the wing supports (E) [Photo C]. Be sure to attach the hinges on the inside faces of the wings, creating three mirrored pairs of wing supports. Use scraps to position and secure the wing supports to the case sides (A) and back (B) [Photo D]. While we show this mobile base with the Bosch GTS1031 benchtop tablesaw (find a review of this saw at woodmagazine.com/ benchtopbosch), the base was designed to fit many similar-size tablesaws. Before building, measure your chosen tablesaw’s dimensions carefully and adjust the base to match your E B saw if necessary. Likewise, measure your router’s height to ensure it fits in the bin. Page 3 of 10 FI LE N A M E: 2 13 Tb lR te rS ta tio n1 _# 10 06 73 40 7. ai D at e: 1 -1 2 Lo rn a J. Fi le na m e: 2 13 Tb ls aw Ro ut er St at io n Lj 1 -1 1, k b 1- 18 #8 x 1 ½ " F .H . s cr ew 2½ " bu tt h in ge #8 x ¾ " F .H . s cr ew #8 x 1 ½ " F .H . s cr ew D us t- co lle ct io n ho le 32 7⁄8 " 29 3⁄8 " 23 7⁄8 " D E A E E E 24 5⁄8 " B E E N N 1" 3¾ " 3¾ " ¾ " 1¼ " ½ " h ol e 1" ¾ " 1" 26 ¼ " 23 7⁄8 " 1½ " 12 " 10 " 1 CA RC A SE Lo ca tio n of C 10 ½ " A FI LE N A M E: 2 13 Tb lR te rS ta tio n1 a_ #1 00 67 34 08 .a i D at e: 1 -1 2 Lo rn a J. Fi le na m e: 2 13 Tb ls aw Ro ut er St at io n Lj 1 -1 1, k b 1- 18 , L P 2- 29 1a W IN G S U PP O RT 10 " 12 " 2" E C A RC A sE 1 W in g s u PP o RT 1a Page 4 of 10 steady parts with a cLaMp A clamp holds the corners of the wing bracing assembly (F/g) flush and steady while you predrill, then secure it with screws. triM up the tops Trim the wing top with a flush-trim bit. set the bit depth so the bearing doesn’t dip into screwhead depressions, which could gouge the edge. G F I G Now give it wings 1From 3⁄4" plywood, cut the wing outer bracing (F), wing bracing (G), and outfeed bracing (H) to size. Then, assemble the bracing with screws [Drawing 2, Photo E]. 2From 1⁄4" medium-density fiberboard (MDF), cut the side wing tops (I) and outfeed top (J) 1⁄8" larger than the width and length listed in the Materials List. Apply a bead of glue to the top edge of each wing bracing assembly (F/G and F/H) and clamp the tops in place [Drawing 2] with 1⁄16" overhang on all sides. After the glue has dried, trim the edges flush [Photo F]. 3Attach 2 1⁄2" butt hinges to the inside of each wing (F/G/I and F/H/J) [Drawing 2], centering the hinge barrel on the bottom edge. Rest one side wing (F/G/I) on the wing supports (E), positioning its front flush with the front of the case. Then secure the hinges to the case. Repeat with the opposite side wing. Then, center the outfeed wing (F/H/J) on the rear wing supports and secure the hinges. shop tip Baseplate helps you target mounting holes with template precision The fine-threaded screws used to table-mount your router require a certain degree of precision when locating mounting holes. Fortunately,your router has a built-in template: its baseplate. Retrieve one of the tray assemblies (K/L/M) for use as the router-table top. Mark a centerpoint for the bit access hole, centered 8 3⁄4" from one end [drawing 3]. Remove and position your router’s baseplate, centered on the marks. Be sure to orient it so that the router, when mounted in the same position, will have its controls easily accessible. Mark the locations of the mounting screws (and lift screw, if your router has one); then, drill and counterbore holes to fit the mounting screws. Next, drill a 1 1⁄2" bit access hole on the center mark. Now, test-fit the router. You may have to purchase longer screws of the same diameter and thread pitch in order to reach the router base. Remove the router to continue the construction. You only need to center the bit access hole to “eyeball” precision. once located, however, hold the subbase firmly to mark the mounting holes accurately. Router subbase Add two trays, fence, and bin 1From 3⁄4" plywood, cut the long edging (K), the short edging (L), and the tray panels (M) to size. Next, assemble the edging with screws before gluing and clamping the panels in place [Drawing 2]. After the glue dries, see the Shop Tip, below, E F F Page 5 of 10 The purchase of these plans does not transfer any copyright or other ownership interest in the plans, the design, or the finished project to the buyer. Buyer may neither reproduce the plans for sale nor offer for sale any copies of the finished project. FILENAME: 213TblRterStation2_#100673409.ai Date: 1-12 Lorna J. Filename: 213TblsawRouterStation Lj 1-11, kb 1-18 2 EXPLODED VIEW ½" washer, lock washer, and nut #8 x 1½" F.H. screws #8 x 1½" F.H. screw 2½" G 2½" butt hinge #8 x ¾" F.H. screw A G I J K M F B C E H F F F GG L N 237⁄8" FCenter on . 2½" 223⁄8" 237⁄8" 237⁄8" 237⁄8" 307⁄8" ¾" 293⁄8" ¼" 237⁄8" 23¾" 237⁄8" 237⁄8" 22¼" ¾" 237⁄8" 2" 3" locking swivel caster F E 3" K L H H I A D #8 x 1½" F.H. screw 1½" 10" 10" ExPlodEd viEW2 Page 6 of 10 to locate the mounting holes for your router in one of the tray assemblies (K/L/M). 2Cut the tray supports (N) to size. To position the lower supports, measure and add the height of your tablesaw table to the height of the tablesaw tray assembly (K/L/M). Measure and mark this distance down from the top edge of the case. Now, use screws to fasten the supports to the case with the top flush with these marks [Drawing 2]. Next, secure the upper tray supports flush with the top of the case. Then, rest the tablesaw tray assembly on the lower tray support, and the router tray assembly on the top tray support. 3Cut the fence face (O) and fence base (P) to size. Lay out and jigsaw the 3"-diameter semicircles, centered, where shown [Drawing 3]. Sand the cuts smooth; then glue and clamp the face to the base. 4 After the glue dries, drill the 1⁄4" pivot holes in the fence (O/P). Position the fence where shown [Drawing 3], and clamp it in place. Using one fence pivot Lay out the pivot sLot for a fuLLy adjustabLe feNce Pivot the fence about 2" away from the bit access hole while drawing a pencil line first on one side of the hole, then the other. Connect the two arcs to complete the pivot-slot layout before drilling the ends and cutting away the waste with a jigsaw. O P Pivot bolt Pivot-slot location The tool trays in this mobile base were made to be compatible with the Bench-tool System from the October 2007 issue of WOOD® magazine. You can find the plan here for a small fee: woodstore.net/besy.html For a free right-angle clamping brace plan, see woodmagazine.com/clampingbrace More Resources Produced by Lucas Peters with Kevin Boyle Project design: John Olson Illustrations: Lorna Johnson 5Cut the bin front and back (Q), bin sides (R), bin bottom (S), and bin cleats (T) to size. Lay out, drill, then jigsaw the handle cutouts in the front and back [Drawing 4]. Then, sand the cuts smooth and round over the edges with a 1⁄8" round-over bit. Assemble the sides, front, and back with screws before gluing and clamping the bottom in place. After the glue is dry, screw the bin cleats to the bin side half in, half out of the bin. 6 Bolt or screw the tablesaw to the tablesaw tray and slide the tray into place. If your tablesaw has a dust- collection port, mark the location and lay out a hole slightly larger than your dust hose [Drawing 1]. Drill a blade start hole and cut out the dust-collection hole with a jigsaw. Mount the router in the router-tray assembly (K/L/M). Store the fence and router accessories in the bin, cap it with the router-table tray, and get to work! hole as a guide, drill through the tray assembly (K/L/M). Remove the clamps and temporarily pin that end of the fence to the table using a 1⁄4" carriage bolt. Now, rotate the fence to mark the location of the pivot slot [Photos G and H], drill 1⁄4" holes at either end of the arc, and cut away the remainder of the slot with a jigsaw. G H Page 7 of 10 FILENAME: 213TblRterStation3_#100673410.ai Date: 1-12 Lorna J. Filename: 213TblsawRouterStation Lj 1-11, kb 1-18 3 ROUTER TRAY 2"-long pivot slot K L M 1½" 11⁄8" 2¼" 1½" hole 3" 22" 9" 8" ¼" pivot holes 3"-diam. arcs ¼" carriage bolt 2" long ¼" knob ¼" washer P O 8¾" RouTER TRAY3 Page 8 of 10 FI LE N A M E: 2 13 Tb lR te rS ta tio n4 _# 10 06 73 41 1. ai D at e: 1 -1 2 Lo rn a J. Fi le na m e: 2 13 Tb ls aw Ro ut er St at io n Lj 1 -1 1, k b 1- 18 4 BI N Q S 23 ¾ " 7" 23 7⁄8 " 7" 22 ¼ " 23 7⁄8 " ¾ " ¾ " ¾ " 87 ⁄8" 4½ " 1¾ " 1½ " h ol e R R Q T T #8 x 1 ¼ " F .H . s cr ew #8 x 1 ½ " F .H . s cr ew 22 ¼ " 2" 1⁄8 " r ou nd -o ve r a lo ng ed ge s of o pe ni ng Bi n 4 Page 9 of 10 Materials List fiNished siZe Part Carcase t w L Matl. qty. A sides 3⁄4" 24 5⁄8" 26 1⁄4" BP 2 B back 3⁄4" 23 7⁄8" 26 1⁄4" BP 1 C shelf 3⁄4" 23 7⁄8" 23 7⁄8" BP 1 D base 3⁄4" 29 3⁄8" 32 7⁄8" BP 1 E wing supports 3⁄4" 10" 12" BP 6 Wings F wing outer bracing 3⁄4" 2 1⁄2" 23 7⁄8" BP 6 G wing bracing 3⁄4" 2 1⁄2" 22 3⁄8" BP 6 H outfeed bracing 3⁄4" 2 1⁄2" 29 3⁄8" BP 3 I* side wing tops 1⁄4" 23 7⁄8" 23 7⁄8" MDF 2 J* outfeed top 1⁄4" 23 7⁄8" 30 7⁄8" MDF 1 Trays K long edging 3⁄4" 2" 23 7⁄8" BP 4 L short edging 3⁄4" 2" 22 1⁄4" BP 4 M tray panels 3⁄4" 23 3⁄4" 23 7⁄8" BP 2 N tray supports 3⁄4" 1" 23 7⁄8" BP 4 Router fence O face 3⁄4" 2 1⁄4" 22" BP 1 P base 3⁄4" 3" 22" BP 1 Router bin Q front and back 3⁄4" 7" 22 1⁄4" BP 2 R sides 3⁄4" 7" 23 7⁄8" BP 2 S bottom 3⁄4" 23 3⁄4" 23 7⁄8" BP 1 T cleats 3⁄4" 2" 22 1⁄4" BP 2 *Parts initially cut oversize. See the instructions. Materials key: BP–birch plywood, MDF–medium-density fiberboard. Supplies: 3" locking swivel casters (4), 1⁄2" washers, lock washers, and nuts (4 each), 2 1⁄2" butt hinges (9 pairs needed), #8×3⁄4" F.H. screws (for hinges), #8×1 1⁄2" F.H. screws, #8×1 1⁄4" F.H. screws; 1⁄4" knobs, 1⁄4×2" carriage bolts, and washers (2 each). Bits: Flush-trim and 1⁄8" round-over router bits; 1 1⁄2" Forstner bit. Page 10 of 10 Cutting Diagram FILENAME: 213TblRterStationCD_#100673412.ai Date: 3-12 Lorna J. Filename: 213TblsawRouterStation Cutting Diagram Lj 3-1 CUTTING DIAGRAM I I J ¼ x 24 x 96" Medium-density �berboard D ¾ x 48 x 48" Birch plywood BA A ¾ x 48 x 96" Birch plywood C E E E E E E SM M PO ¾ x 48 x 96" Birch plywood T QR R Q H G L T KN N FF The purchase of these plans does not transfer any copyright or other ownership interest in the plans, the design, or the finished project to the buyer. Buyer may neither reproduce the plans for sale nor offer for sale any copies of the finished project. On this info-filled disc you’ll find more than... Includes an easy-to-use article index! For more product information or updated versions of thisDVD-ROM, go to woodmagazine.com/DVDLibrary W OOD M agazine Septem ber 1984 – D ec/Jan 2011/2012 Issues 1–209 325 Furniture Projects 270 Shop Projects 940 Weekend Projects 6 45 1,70 0 Shop Tips 875 Tool Reviews and Features Skill-Building Techniques Issues 1–209 Easy-to-makeWine Cabinet WOOD Better Homes and Gardens® ISSUE 172 OCTOBER 2006 D ® W OOD 172 O C TO B ER 2006 $6.99 U.S. / $7.95 CAN. Display until October 10, 2006 A GREAT WEEKEND PROJECT! p.82 END-GRAIN CUTTING BOARD 21 Workshop Clutter Busters p.90 Add to Your Skills• Cut Perfectly Straight Edges p.76• Tune Up your Bandsaw p.52• Kerf-Bend Plywood p.32 Improve Your Shop• Space-saving Tool Storage p.46• 10 Air Cleaners Tested p.70 Better Homes and Gardens® ISSUE 178 SEPTEMBER 2007 ® FREE FULL-SIZE PATTERNS INSIDE TE ACH KI DS WOO DWO R KI NG : A PROVE N 4 -STE P PL AN ! $6.99 U.S. / $7.95 CAN. Display until August 28, 2007 Heirloom CradleCraft it this weekend.Cherish it for generations. 47 Time- and Money-Saving Tips Inside! 20 Tools Tested • 12" Mitersaws • Parallel Jaw Clamps • Steel Rules More Great Projects • Space-saving Outfeed Table • Tablesaw Alignment Jig • Catchall Box • Tower Shelves • Bistro Stool Build Your Skills• Clamping Secrets • No-slip Miters • Template Routing • Faux Finishes Stores flat in it’s own case! Better Homes and Gardens® ISSUE 186 OCTOBER 2008 ® $6.99 U.S. D is p la y u n ti l O ct o b er 7 , 2 0 08 11 Easy-to-Build Projects Inside 200 m.p.h. & made of wood!You need to see it to believe it. p. 50 TRIO OF TABLES p.32 CHINESE CHECKERS p.72 MITERSAW STAND p.44 EXCLUSIVE! PLUS 31 TOOLS TESTED IN THIS ISSUEWO OD We Test & Rank the Newest 18-Volt Lithium-Ion Drills ISSUE 209 DEC/JAN 2011/2012 Better Homes and Gardens® Tur n Stock C abinets into Fur ni ture! p.32 Make this tall chest, and other fine furniture, the EASY way.Great Projects! Jewelry Box p.38 Carousel Music Box p.45Backgammon Board p.50Rockin’ Truck p.63 We Test & Rank the Newest 18-Volt Lithium-Ion Drills p.58 $6.99 U.S. Display until January 17, 2012 ® 53Shop Tips Inside! September 1984 – Dec/Jan 2011/2012 In a Searchable Digital Format 27 Years of Issues! WOOD® Complete Back Issues NOTICE: Reproduction or distribution of the content of this product is strictly prohibited. Purchase of this product does not transfer any title or rights of own- ership in the content to the purchaser. The content of this product is protected by copyright and may not be used for any other purpose without the written permission of the copyright owner. © Copyright Meredith Corporation 2012. All rights reserved. Produced in the USA. Browse more than 1,300 woodworking project plans, DVDs, back-issue collections, videos, tool reviews, books, & more. Everybody’s a tool critic. Now it’s your turn! 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